Page 1 of 23

Subcontractor’s Name : ARABI ENERTECH. KSC

Subcontractor No. : 0-6798-Z-3160-003

Project Name : KNPC Clean Fuel Project

Subcontractor Work Package : SMP Construction Work- (SK Brown Revamp)

DOCUMENT TITLE : PROCEDURE FOR PIPING FABRICATION

Subcontractor’s Doc. No. : VS3160-003-A-2013

KNPC CLEAN FUELS PROJECT

Subcontractor
ISSUE PURPOSE: FA FR FI  FC AB
Approval or review hereunder shall not [ be construed to relieve Vendor / Subcontractor of his
T
responsibilities and liability under the Contract.
y CTR DEPT. /
Contractor Review Result
p SIGNATURE
√ 1. Approvede / No Comments I.G Yoo
2. Approved / Reviewed - Minor Comments QCM
3. Rejecteda- Commen s as Noted
/
4. Rejected
Unnikrishnan /
5. q
Not Reviewed
u
QC
JOB. NO. o 0-6798-20-0000
t
COMPANY REV
DOC.no. P6011MAA.000.10.51.4762
e

f
V plus Purchaser Code (V/J/G/S) & Subcontract No. - SERIAL no. F1
Contractor r
DOC.no. VS3160-003-A-2013
o
m
KNPC CFP Project DSN:
MAA Package 33248
REVIEW BY: t DISCIPLINE: DATE:
CODE: h
1 S.M.Logan Const. 07.11.2018
e
A REVIEW CODE: 1: Approved\No Comments; 2: Minor Comments;

INDTR 1|Page
3: Comments as Noted; 4: Rejected
-2018
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VS3160-003-A-2013 REV .F1

ARABI ENERTECH K.S.C

COMMENTS RESPONSE SHEET

Doc. No.: VS3160-003-A-2013 (Rev. F1)

Doc. Name: Procedure for Piping Fabrication
Client: SKEC / KNPC – MAA
Date 22-Oct-2018
Project Clean Fuels Project – KNPC MAA Refinery

Sl. No. Company / Contractor Comments Response

Incorporated
Contractor to specify RT percentage for socket weld
1 joints.
5% of Radiography Test will be done for Socket welds
coming under Arabi Enertech scope of works.

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PROJECT: Document ID Code:

KNPC CLEAN FUELS PROJECT
VS3160-003-A-2013
Rev.
PROCEDURE FOR PIPNG FABRICATION(AE) F1

Record of Revisions

Rev. No. Date Description

O1 29-Feb-16 Issued for Comments

A1 08-Mar-16 Issued for Review

A2 27-Apr-16 Issued for Review

F1 22-Oct-18 Issued for Final

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PROJECT: Document ID Code:

KNPC CLEAN FUELS PROJECT
VS3160-003-A-2013
Rev.
PROCEDURE FOR PIPNG FABRICATION(AE) F1

Project Title : MAA (BROWN FIELD REVAMP)

KNPC – CFP MAA PROJECT

Document Title : PROCEDURE FOR PIPNG FABRICATION

(ARABI ENERETECH)

Subcontractor Document No. : VS 3160-003-A-2013

F1 22-OCT-18 Issued for Final DHARVAS A.S.RAJA M.SURESHKUMAR

A2 27-APR-16 Issued for Review RAJESH.R.P A.S.RAJA M.SURESHKUMAR

A1 08-MAR-16 Issued for Review RAJESH.R.P M.SURESHKUMAR M.SURESHKUMAR

O1 29-FEB-16 Issued for Comments RAJESH.R.P M.SURESHKUMAR M.SURESHKUMAR

REV DATE DESCRIPTION PREPARED BY CHECKED BY APPROVED BY

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PROJECT: Document ID Code:

KNPC CLEAN FUELS PROJECT
VS3160-003-A-2013
Rev.
PROCEDURE FOR PIPNG FABRICATION(AE) F1

TABLE OF CONTENT

1.0 Purpose -------------------------------------------------------------------------------- 5

2.0 Scope ---------------------------------------------------------------------------------- 5

3.0 References ---------------------------------------------------------------------------- 5

4.0 Definitions ---------------------------------------------------------------------------- 6

5.0 Procedure ----------------------------------------------------------------------------- 7

5.1 General -------------------------------------------------------------------------------- 7

5.2 Responsibilities ----------------------------------------------------------------------- 7

5.3 Materials ------------------------------------------------------------------------------- 9

5.4 Material Traceability----------------------------------------------------------------- 9

5.5 Shop Fabrication Process ------------------------------------------------------------ 10

5.6 Dimensional Tolerances ------------------------------------------------------------- 13

5.7 Pipe Support Pre Fabrication ------------------------------------------------------- 14

5.8 Repair of Weldments ----------------------------------------------------------------- 14

5.9 Spool Management ------------------------------------------------------------------- 15

5.10 Pipe Spools Pressure Testing------------------------------------------------------- 16

6.0 Attachments -------------------------------------------------------------------------- 16-22

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PROJECT: Document ID Code:

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VS3160-003-A-2013
Rev.
PROCEDURE FOR PIPNG FABRICATION(AE) F1

1. PURPOSE

The purpose of this procedure is to provide the minimum requirements for the Fabrication of
Process Piping to meet the specific contractual specifications and requirements of the project –
Clean Fuels Project (CFP – MAA).

2. SCOPE

This procedure applies to project – Clean Fuels Project (CFP – MAA), for the fabrication of Carbon
Steel, and Pipe supports in compliance with project specifications.

3. REFERENCES

Project compliance audits will be conducted based on the following documents:

3.1 DEP 30.10.02.11-Gen - Metallic materials–selected standards
3.2 DEP 30.10.02.17-Gen. - Wet H2S requirements for downstream pressure vessels and piping
3.3 DEP 30.10.02.31-Gen - Metallic materials–Prevention of brittle fracture
3.4 30.10.02.31-P6000CFP-000-PV - Project Variation to DEP 30.10.02.31
3.5 DEP 30.10.60.18-Gen. - Welding of metals (amendments/ supplements to API RP 582)
3.6 30.10.60.18-P6000CFP-000-PV - Project Variation to DEP 30.10.60.18
3.7 DEP 31.10.00.10-Gen. - Positive material identification (PMI) program
3.8 31.10.00.10-P6000CFP-000-PV - Project Variation to DEP 31.10.00.10
3.9 DEP 31.38.01.10-Gen - Piping classes – basis of design
3.10 31.38.01.10-P6000CFP-000-PV - Project Variation to DEP 31.38.01.10
3.11 DEP 31.38.01.11-Gen - Piping – General requirements
3.12 31.38.01.11-P6000CFP-000-PV - Project Variation to DEP 31.38.01.11
3.13 DEP 31.38.01.12-Gen - Piping classes – refining and chemicals
3.14 DEP 31.38.01.13-Gen - Compilation of bill of material for piping isometrics
3.15 31.38.01.13-P6000CFP-000-PV - Project Variation to DEP 31.38.01.13
3.16 DEP 31.38.01.29-Gen. - Pipe Supports
3.17 31.38.01.29-P6000CFP-000-PV - Project Variation to DEP 31.38.01.29
3.18 DEP 31.38.01.31-Gen - Shop and field fabrication of piping
3.19 31.38.01.31-P6000CFP-000-PV - Project Variation to DEP 31.38.01.31
3.20 DEP 74.00.10.10-Gen - Shop and Field Pressure Testing of Piping Systems
A
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Rev.
PROCEDURE FOR PIPNG FABRICATION(AE) F1

3.21 74.00.10.10-P6000CFP-000-PV - Project Variation to DEP 74.00.10.10

3.22 ASME B 31.3 - Process Piping
3.23 ASME Section IX - Welding and Brazing Qualifications
3.24 ASME Section V - Non Destructive Examination
3.25 ASME Section VIII - Rules for Construction of Pressure Vessels
3.26 S-000-13A0-0003V - General Specification for Identification Mark & Lettering
3.27 S-000-1360-0002V - Piping Material Specification
3.28 S-000-1360-0004V - Specification for Identification of Piping Materials
3.29 S-000-1520-0106V - Control of Monitoring & Measuring Devices
3.30 S-000-1520-0201V - Supplementary Welding Requirement for KNPC Project
3.31 S-000-1630-0001V - Site Material Control Procedure (Contractor)
3.32 S-000-1670-0001V - Site Quality Plan (Contractor)
3.33 S-000-1670-0101V - Nonconformity Control Procedure at Site (Contractor)
3.34 S-000-1630-0001V - Material Control Procedure
3.35 S-000-1654-0233V - Cutting, Welding and Grinding Procedure
3.36 S-000-1670-0001S - Welder Qualification and Control Procedure
3.37 H-000-1536-0001S - Welding Consumable Control Procedure
3.38 S-000-3168-0002V - Procedure for Piping Pressure Testing

4.0 TERMS AND DEFINITIONS

4.1 Company - Kuwait National Petroleum Company (K.S.C)
4.2 Contractor -SK Engineering & Construction (SK E&C)
4.3 Sub-Contractor - ARABI ENERTECH.KSC(AE)
4.4 Project - Clean Fuels Project (CFP – MAA)
4.5 Low-Tier Sub Contractor - Firm/ Company to whom any part of the works is sub contracted
under the responsibility of sub-contractor and includes any supplier of materials to be
supplied by the sub-contractor for use in the works.

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PROCEDURE FOR PIPNG FABRICATION(AE) F1

4.5 Abbreviations
4.5.1 ASME - American Society of Mechanical Engineers
4.5.2 AWS - American Welding Society
4.5.3 BPV Code - Boiler and Pressure Vessel Code
4.5.4 NPT – National Pipe Thread
4.5.5 DSS - Duplex Stainless Steel
4.5.6 HSE - Health, Safety & Environment
4.5.7 ITP - Inspection and Test Plan
4.5.8 PPE - Personal Protective Equipment
4.5.9 PQR - Procedure Qualification Record
4.5.10 WPS - Welding Procedure Specification
4.5.11 QA/QC - Quality Assurance / Quality Control
4.5.12 RFF - Request for Fabrication
4.5.13 FFW – Field Fit Weld
4.5.14 WQT - Welder Qualification Test

5.0 PROCEDURE

5.1 General
5.1.1 Fabrication of piping shall be performed in accordance with the Company approved
construction drawings, piping codes, contract specifications, company standards and this
procedure.

5.2 Responsibilities

5.2.1 Project Manager

1. Direct and manage the activities of Project and support personnel in the planning,
scheduling and execution of fabrication work.
2. Evaluate monthly progress reports; describing the schedule, manpower expenditures and
work scope for accuracy, completeness and timeliness.
3. Develop and implement administrative, technical and corporate procedures and policies to
ensure the successful operation of the fabrication in respect of Project HSE and Quality
Policies.
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5.2.2 QA/QC Engineer

1. Implement & Monitor the Quality Management System and Approved QC Plan at site.
2. Develop and establish PQR, WPS and Procedures.
3. Develop Audit schedule and conduct Internal Audits accordingly.
4. Ensure all quality control documentation is in place and up-to-date.
5. Control all non-conformance reports and monitor implementation of corrective and
preventive action.
6. Coordinate with the construction manager on evaluation & correction of all quality issues.
7. Participate the weekly QA/QC meetings with the Contractor to discuss the Quality action
plans.
8. Develop and maintain written procedures for quality control/quality assurance in the
process of fabrication.
9. Coordinate as necessary with the Contractor in the evaluation and correction of specific
quality control problems and issues related to piping fabrication.
11. Monitoring Performance of NDE as per piping classes in line with fabrication.
12. Monitoring Welder performance periodically and implement improvement measure if
necessary in coordination with QC Inspectors/ welding supervisors.
13. Managing the continuous Quality training & periodic assessment of QC staff.

5.2.3 QC Inspector
1. Perform routine inspection for qualifications of personnel, materials, workmanship,
procedure implementation, welding consumables and equipment.
2. Coordinate for conducting NDE as per project requirement.
3. Determine defect analysis, trends and propose corrective or improvement measures if
necessary.
4. Attend site meetings with construction and highlight observation & ensure project quality
requirements are fully met.

5.2.4 Piping Engineer

1. Responsible for the execution of the piping fabrication and ensuring that the work is
performed conforming to the Project safety & Quality policies and without environmental
impact.
2. Manage and assign responsibilities for construction supervisors and foremen to obtain the
most effective utilization of resources to meet fabrication schedule & budget.
3. Regularly follow-up on progress of fabrication and ensure that construction objectives are
met and determine an action plan.

5.2.5 Planning Engineer

1. Evaluates Field Design Changes/ Change Orders and interfaces with the technical
department for the initiation, development and close out of modifications.
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2. Coordinate with QC department for timely accomplishment of QC Inspections.

5.2.6 Construction Supervisor

1. Responsible for coordinating fabrication activities through the contractor's supervision with
respect to HSE, working practices, quality and timely execution of the works.
2. Coordinate with site QC team for performing in-process inspections.
3. Conduct Site meetings for explaining work methodologies, safety & Quality requirements.

5.2.7 Welding Foreman

1. To manage and supervise the overall welding works effectively to achieve the production
targets with quality compliance.
2. To assist in establishing the welding resources and manage resources to achieve fabrication
completion within schedule.
3. To liaise with Quality Control Engineer/ Welding Service Unit for Welders Qualification,
welding filler metal requirement and WPS& PQR requirements.

5.3 Materials
5.3.1 The materials used for piping fabrication shall conform to the requirements of DEP
30.10.02.11. Materials not specified in DEP 30.10.02.11, may be used for fabrication upon
approval from the Company. Material receiving, inspection and issuing shall be controlled in
accordance with Material Control Procedure S-000-1630-0001V.

5.3.2 Welding consumables used for piping fabrication shall be approved by the Contractor/
Company prior to fabrication and shall conform to relevant ASME/AWS specifications. The
procurement and control of welding consumables shall be as per welding consumable
control procedure H-000-1536-0001S.

5.4 Material Traceability

5.4.1 The manufacturer’s identification of material shall be preserved throughout the pipe
fabrication and erection process. Off cuts shall have Heat Numbers, Material Standard &
Grade transferred immediately prior to making the cut. Marking of materials shall be done
by paint marker.
Traceability shall be achieved by recording manufacturers heat/batch numbers on Daily
Welding Report (JGSK-QC-6000-07) and Weld Inspection Summary Record (JGSK-QC-6000-
06) during fabrication and erection.

5.4.2 Pipe spools for CFP-MAA package (Brown Revamp) with SK E&C shall be color coated with
“BLUE” to distinguish.

5.4.3 Contractor shall ensure that the true certified copy of Material Test Certificates from Vendor
for all piping components used in shop and field fabrication shall be made available and
retained for reference. Random verification for material traceability shall be carried out
during fabrication phase by the QC Inspector.

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5.5 Shop Fabrication Process

5.5.1 Contractor shall ensure that the relevant approved fabrication drawings are of the latest
revision. Isometric drawing shall have detailed dimensions, type and grade of materials, NDE
requirements and the extent to which welded joints shall be applied.

5.5.2 Standard workmanship practices shall be followed during all the fabrication and welding
activities. All approved WPS shall be available and posted near the workplace.

5.5.3 All ‘O-let’, pipe stubs and reinforcing pad branch connections welded to the main pipe shall
be shop fabricated in majority and in case of non-availability of materials; the same shall be
accomplished at field.

5.5.4 Care shall be taken that tools used on one material grade shall not be subsequently used on
any other material grade. These tools shall be identified by colour coding. Pipe supports/
stands shall be properly covered to avoid direct contact with any foreign materials.

5.5.5 Cutting and Beveling

5.5.5.1 Cutting and beveling of pipes may be done by mechanical means: flame cutting or plasma
cutting. The following shall apply:
a) For carbon steel, flame (or arc) cuts shall be reasonably smooth and all oxides shall
be removed from the surface by grinding to bright metal.

5.5.5.2 Pipe end preparation/bevel preparation for welding shall be in accordance with the
approved WPS to be used for the joints. Surface shall be smooth, true and free from tears,
visible cracks and visible lamination. The internal and external surfaces at the cut edge shall
be cleaned for a minimum of 25mm from the pipe end.

5.5.5.3 Joining pipe and fitting of different wall thickness; the inside of the thicker pipe/fitting Shall
be chamfered by grinding or machining as per Fig. 328.4.3 of ASME B31.3.

5.5.5.4 Galvanized materials shall be cut using 'cold' cutting methods.

5.5.5.5 Pipes for socket weld joints shall be cut square and burrs removed.

5.5.6 Assembling of Piping Components

5.5.6.1 For butt-welding of all piping components (e.g. pipe ends, fittings and welding neck flanges),
a uniform root gap shall be provided as specified in the relevant Welding Procedure
Specification.

5.5.6.2 Tack welding shall be carried out by qualified welders. Tack welding using pieces of bar in
the groove shall not be allowed. Temporary tack welds shall be removed by grinding or
chipping and the area shall be ground smooth without reduction of wall thickness, followed
by MT or PT inspection to confirm the absence of linear indications except P1 material.
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5.5.6.3 The minimum distance between the edges of two pressure-containing welds shall be Twice
the wall thickness of the thicker pressure part. The same requirement applies to the
instance between non-pressure attachment welds and a pressure-containing weld in order
to allow non-destructive inspection of the pressure-containing weld. If it is not attainable
for attachment welds or RF pads, the covered welded joint shall be ground smooth and
radio graphically examined over its entire covered length, plus 38 mm on each side (as per
para 341.4.1 (I) of ASME B 31.3) subject to Company approval.

5.5.6.4 Longitudinal welds in two adjacent pipes should be 180° apart, but in any case shall be
separated by at least twice the wall thickness of the thicker pipe. If the pipe contains a
longitudinal weld, this weld shall not be located at the bottom of the pipe after installation,
it shall be located at least 45° from the bottom of the pipe. Shop fabrication of spools shall
be done foreseeing these requirements for field welds.

5.5.6.5 Flange shall be oriented such that the bolt holes straddle the horizontal (north/south) and
vertical centerlines, except specifically mentioned in the piping drawings. Radial grooves or
scratches on flange faces exceeding limits specified in ASME B 16.5 Table 3 are not allowed.
Any re-facing of flange face is not allowed.

5.5.6.6 Wherever Field Fit Weld (FFW) is marked in the isometric drawing(s), an extra pipe length of
200mm with plain end shall be provided for field adjustments.

5.5.7 Welding
5.5.7.1 All welding shall be in accordance with DEP 30.10.60.18-Gen, S-000-1520-0201V and ASME
B31.3/ Approved WPS.
5.5.7.2 Qualification of welding procedure and welders shall be in accordance with 30.10.60.18-
P6000CFP-000-PV, API 582, S-000-1520-0201V, AWS D1.1 and ASME BPV Code Section IX.
Qualified thickness range shall be as per ASME B31.3 Table
323.3.1 Column A-5 if impact test is applicable.

5.5.7.3 All the welding consumables (including Tack Weld consumables) shall be handled
/controlled as per H-000-1536-0001S.

5.5.7.4 Only Company approved Welding Procedures shall be used for welding. Controlled copies of
approved WPS shall be displayed in work places where they will be applied or all approved
WPS shall be posted in a board located in strategic location.

5.5.7.5 Only Company approved welders shall be allowed for tack and production welding as per
the relevant Company approved welding procedures.

5.5.7.6 The Gas Tungsten Arc Welding (GTAW) process shall be used for

i. Root welding of all pipe sizes and

ii. Full welding of pipes, branch fittings and flanges in sizes DN 50 (NPS 2) and smaller.

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5.5.7.7 Welding operations shall be suitably protected from adverse weather conditions including
rain and blowing sand. Open pipe ends shall be covered to prevent any through draught.

5.5.7.8 Vertical welding shall be performed vertical up direction only. Vertical down welding shall
be subjected to Company approval.

5.5.7.9 Weld peening is prohibited in all weld passes.

5.5.7.10 Galvanized, coated, primed or painted surfaces shall be removed to clean metal for a
minimum distance of 75mm from the intended weld Bevel/end.

5.5.7.11 Pre-heat and inter pass temperature specified in the Company approved Welding
Procedure Specification shall be adhered.

5.5.7.12 Weld inter pass cleaning shall be by power brush and/or grinder. All slag shall be removed
before deposition of succeeding passes.

5.5.7.13 Whenever a back purging gas is used to prevent oxidation or scale formation on the
underside of the weld, the purge shall be maintained until at least 6.5mm depth of weld
metal has been deposited or until the completion of the weld whichever is lesser.

5.5.7.14 Whenever practical, welds shall be completed in one heat cycle, once started. Welds shall
have half the wall thickness or three layers deposited (whichever is higher) if welding is
suspended prior to completion. If Preheat other than ambient temperature is specified in
WPS, the weld shall be completed before the preheat temperature is lowered, except that
intermediate lowering of preheat temperature shall be permitted for unalloyed steels if at
least 50% of the weld has been completed. The joint shall be cooled under insulation.
Preheating shall be restored to the specified temperature and maintained for 30 minutes
before welding is recommenced.

5.5.7.15 The weld number (Joint No.) and welder identification number shall be marked with Paint
marker next to each weld. The joint number identification of repair welds shall be suffixed
with R1, R2 etc. and the cut & re-weld joints with C1, C2 etc.

5.5.7.16 Register of welder and welding operator qualification and certificates shall be maintained
on site / fabrication shop office.

5.5.8 Distortion Control

5.5.8.1 Due allowance for weld shrinkage shall be made during fabrication. Every effort shall be
made to reduce misalignment by rotation of pipes to achieve the best fit-up. Support
locations shall be ensured for not fouling with weld seam on the pipe.

5.5.8.2 Piping components shall be adequately supported, aligned by clamps, jigs or other suitable
device.

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5.5.8.3 Heating or introduction of detrimental strain to correct distortion in equipment or piping

component is prohibited.

5.5.9 Welded Branch Connections

5.5.9.1 Figures 328.5.4A through 328.5.4E of ASME B 31.3 show acceptable details of branch
connections with and without added reinforcement, in which the branch pipe is connected
directly to the run pipe.

5.5.9.2Figure 328.5.4D of ASME B 31.3 shows basic types of weld attachments used in the
fabrication of branch connections. The location and minimum size of attachment welds shall
conform to these requirements.

5.5.10 Fillet and Socket Welds

5.5.10.1 The size of a fillet weld is determined as shown in ASME B 31.3, Fig. 328.5.2A. Fillet welds
shall have a minimum of two passes with weld throat not less than 6mm.

5.5.10.2 Typical weld details for slip-on and socket welding flanges are shown in ASME B31.3, Fig.
328.5.2B; minimum welding dimensions for other socket welding components are shown in
ASME B 31.3 Fig. 328.5.2C. Socket joint gap checking may be selectively applied to check
that a fit-up gap remains after the weld has been made as per DEP 31.38.01.11 clause
8.3.1.2.2.

5.5.10.3 Socket joint assembly shall be spaced by gap 2 mm during fit-up to attain a gap of 1.0 - 1.5
mm after welding to avoid bottoming of the joint. This can be verified by marking the gap
outside the fit-up and marking shall be inspected visually during fit-up inspection. After the
welding the gap shall be verified visually/ by random radiography. During welding of the
valve, the closure member shall be in the open position - P6011MAA.000.10.51.3136.
5% of Radiography Test will be done for Socket welds coming under Arabi Enertech scope of
works.

5.5.11Threaded Connection
5.5.11.1 Pipe thread sealant shall be used for threaded connection except where seal welding
is required. The pipe thread sealant material shall be compatible with the piping material
and service fluid and shall be approved by Company prior to use.
5.5.11.2 All threads shall be tapered (NPT) and concentric to the outside of the pipe and the last
three threads of the joint shall not be engaged
5.5.11.3 Ends shall be clean cut and free from burrs or stripping of threads.

5.6 Dimensional Tolerances

5.6.1 The following dimensional tolerances shall be adhered to during fabrication & linear
tolerances shall not be cumulative:

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PROJECT: Document ID Code:

KNPC CLEAN FUELS PROJECT
VS3160-003-A-2013
Rev.
PROCEDURE FOR PIPNG FABRICATION(AE) F1

5.7 Pipe Support Pre fabrication

5.7.1 Pipe support attachments on the shop fabricated spool shall be welded on to the pipe spools
at the locations as shown in the drawing. Support attachments for field piping shall be field
fabricated and installed.
5.7.2 Support materials welded directly to the pipe shall be indicated on the piping
isometric drawing and be of the same type of material as the pipe.
5.7.3 Auxiliary pipe supports such as guides, anchors and miscellaneous supports shall be field
fabricated and installed.

5.7.4 If pipe stanchions or dummy legs are welded to elbows or tees, a distance of at least 50 mm
(2 in) shall be kept between the welds of the support and the welds of the fitting. If it is not
attainable, the covered weld seam length (plus 50mm on both sides of the intersecting
weld) of the fitting shall be ground smooth. The support shall be installed after ensuring the
ground area is free of any internal defects by MT/PT examination.
5.7.5 For reinforcement pads & saddles, 6mm threaded vent holes to be provided before welding.
Holes shall be sealed with suitable sealing compound after the completion of leak test.
5.7.6 Primary pipe support welding shall be reported in (JGSK-QC-6000-07).

5.8 Repair of Weldments

5.8.1 Weld defect to be repaired shall be removed to sound metal. Repair joints shall be welded
using a qualified welding procedure specification, recognizing that the cavity to be repaired
may differ in contour and dimensions from the original joint. Repair joints shall be welded by
qualified welders or welding operators. Preheating and heat treatment shall be as required
for the original welding.

5.8.2 A Weld Repair Log / Welder Performance Log shall be maintained detailing the repair rate
for each qualified welder/welding operator. Any welder /welding operator with

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PROJECT: Document ID Code:

KNPC CLEAN FUELS PROJECT
VS3160-003-A-2013
Rev.
PROCEDURE FOR PIPNG FABRICATION(AE) F1

unacceptable repair percentage (>3% film wise) shall be disqualified from the job, followed
by additional training and requalification.

5.8.3 For spot and random NDE, additional two joints shall be examined for each repair found and
shall be identified with suffix P1, P2, etc. as per the requirements of progressive sampling
for examination given in ASME B31.3 Para 341.3.4. These welds shall be recorded and
monitored in a Weld Repair Log (Attachment)
1). In case any defective weld joint is repaired or replaced, re-examined, progressive
sampling shall be followed in accordance to section 341.3.4 (f) of ASME B31.3.

5.9 Spool Management

5.9.1 The spools ready for further processes shall be lifted and moved by the use of suitable nylon
slings or lifting hooks, equipped with non-metallic bevel protectors by suitable means. All
the spools being shifted should bear a proper identification/ color coding (by using polyester
color ribbons) as per the following table:

Activity Color Band

Spools shifted from shop to NDE storage
area after welding completion inspections White Band
Spools for Radiography Yellow Band
Spools for PWHT Red Band
Spools for PT/MT Blue Band
Spools for PMI Pink Band
Spools Released for Painting Green Band

5.9.2 All spools shall have printed bar code with isometric number and spool identification stuck
(one inside the spool & one outside) or stamped on metal tags, wired to the spool CS tag for
Carbon steel. Hard stamping shall not be used on the spool surface.

5.9.3 Protect flange surfaces and beveled weld ends of prefabricated pipes with wooden covers,
vinyl caps. Ensure end capping of straight pipes, pipe spools, pipe fittings, valves etc. during
shop storage and for sending to site. Ensure pipe spool lay down area is properly drained,
spools properly supported off the ground.

5.9.4 All spools shall be internally cleaned to remove debris that could hamper radiography,
pressure testing or process fluids. Cleaned spools ends shall be masked off immediately.

5.9.5 Spools can be released for further activities after completion of required PWHT/ NDE as per
piping/ line class and signed-off Daily Welding Report (JGSK-QC-6000-07), Weld Inspection
Summary Record (JGSK-QC-6000-06). “WPS number” shall be provided instead of “welding
electrodes/wire details “in Weld Inspection Summary Record (JGSK-QC- 6000-06).

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PROJECT: Document ID Code:

KNPC CLEAN FUELS PROJECT
VS3160-003-A-2013
Rev.
PROCEDURE FOR PIPNG FABRICATION(AE) F1

5.10 Pipe Spools Pressure Testing

5.10.1 If pipe spools cannot be tested as a part of whole piping system at site due to any
engineering or practical reasons, the same may be tested in the shop.

5.10.2 Flushing and Hydrostatic Pressure Testing of the piping shall be carried out as per
S-000-3168-0002V

6.0 ATTACHMENTS

6.1 Attachment 1 - Weld Repair Log

6.2 Attachment 2 - NDE Request

7.0 REFERENCE ATTACHMENTS

7.1 S-000-1670-0401V (JGSK-QC-6000-06) - Weld Inspection/ NDT Summary Report

7.2 S-000-1670-0401V (JGSK-QC-6000-07) - Daily Welding Inspection Report
7.3 S-000-1670-0401V (JGSK-QC-6000-18) - Spool and Support Release Notice
7.4 S-000-1670-0401V (JGSK-QC-6000-34) - Leak Test Report for Reinforcing Pad

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VS3160-003-A-2013 REV. F1

WELD REPAIR LOG

COMPANY :KUWAIT NATIONAL PETROLEUM COMPANY(K.S.C) CONTRACTNO. :0-6798-Z-3160-003
PROJECT :CLEANFUELSPROJECT(CFP) PROJECT No. :
CONTRACTOR :SKE&C DATE
SUBCONTRACTOR :ARABI ENERTECH(AE)
Sl Joint Welder Date of Rejected RT Type of Accepted RT
Line Number ISO Number Rev No. Sheet No. Joint No. Remarks
No. Size Sch/Thk No. Welding Report No. Defects Report no.

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VS3160-003-A-2013 REV. F1

NDE REQUEST
COMPANY :KUWAIT NATIONAL PETROLEUM COMPANY(K.S.C) CONTRACTNO.:0-6798-Z-3168-003

PROJECT :CLEANFUELSPROJECT(CFP) PROJECTNO. :

CONTRACTOR :SK E&C NDE REQUEST NO.

SUBCONTRACTOR :ARABI ENERTECH (AE) DATE

TYPEOFNDE: NDESUBCONTRACTOR:

PIPING FLUID
SL.NO. LINENO. ISOMETRICNO. SHT.NO. REVNO. SPOOLNO. JOINTNO. WELDTYPE SIZE THICKNESS WELDERNO. MATERIAL LOCATION REMARKS
CLASS CATEGORY

REQUESTEDBY(SUBCONTRACTOR) RECEIVEDBY(NDESUBCONTRACTOR)

NAME

DESIGNATION

SIGNATURE

DATE

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Kuwait National Petroleum Company (K.S.C.) VS3160-003-A-2013 REV .F1
Clean Fuels Project - Project Coordination Group- EPC PKG-1

System No: Tag ID: ITR No.:

WELD INSPECTION / NDT SUMMARY REPORT

Contract No. : Sub Contractor : Date :
Line No. / Iso Dwg. No. : Reference Std. : NFI No. :
WELD DATE REPORT NO.
BASE METAL-1 BASE METAL-2 TYPE OF SIZE/ WELDER
JOINT OF WPS NO PMI/
WELD SCHEDULE NO. MT/PT RT/UT PWHT HARDNESS REMARKS
NO. SPEC. HEAT NO. SPEC. HEAT NO. WELDING Ferrite

NOTE :
1) PWHT & NDE ARE AS PER CONTRACT SPECIFICATIONS.
2) PWHT & NDE WERE WITNESSED AND / OR REVIEWED.
3) ALL MATERIAL USED ARE AS PER CONTRACT SPECIFICATION.

SUB CONTRACTOR QC INSPECTOR CONTRACTOR QC INSPECTOR COMPANY QC INSPECTOR

SIGNATURE : SIGNATURE : SIGNATURE :
NAME : NAME : NAME :
DATE : DATE : DATE :

BASE METAL NUMBERING SHALL FOLLOW PROCESS FLOW DIRECTION

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* FILLET WELD - FW
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Kuwait National Petroleum Company (K.S.C.) VS3160-003-A-2013 REV .F1
Clean Fuels Project - Project Coordination Group- EPC PKG-1

System No: Tag ID: ITR No.:

DAILY WELDING INSPECTION REPORT

Welding Date:
NFI No.: Contract No. : Sub Contractor:
Reference Std.:
WELD BASE METAL-1 BASE METAL-2 TYPE Welder No.
LINE NO. / Joint Dia / FIT-UP Welding WPS VISUAL
JOINT OF REMARKS
ISO DRG. No. Thk. INSP. Process No. INSP.
NO. SPEC. HEAT NO. SPEC. HEAT NO. WELD Root Cap

SB – Shop Butt Weld, FB – Field Butt Weld, SF – Shop Fillet Weld, FF – Field Fillet Weld, ST – Shop Threaded Joint, FT – Field Threaded Joint, SS – Shop Support Weld, FS – Field Support Weld,
Weld Type Abbreviation: SR – Shop Reinforcement Pad Weld, FR – Field Reinforcement Pad Weld, SBT – Shop Buttering Weld, FBT – Field Buttering Weld, SOL – Shop Olet Weld, FOL – Field Olet Weld,
(Sample) STF – Shop Threaded Requires Seal Weld, FTF – Field Threaded Requires Seal Weld,
SJK – Shop Jacketed Piping Joint (For Outer Jacket Piping Only), FJK – Field Jacketed Piping Joint (For Outer Jacket Piping Only)

SUB CONTRACTOR QC
CONTRACTOR QC INSPECTOR COMPANY QC INSPECTOR
INSPECTOR
NAME : NAME : NAME :
SIGNATURE : SIGNATURE : SIGNATURE :
DATE :
D R A DATE : DATE :
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VS3160-003-A-2013 REV .F1

Kuwait National Petroleum Company (K.S.C.)

Clean Fuels Project - Project Coordination Group- EPC PKG-1

System No: Tag ID: ITR No.:

Spool and Support Release Notice

NFI NO.: PCWBS NO.: INSPECTION DATE:
TAG/ID DESCRIPTION: DWG. NO. & REV. NO.:
REFERENCE STD.:

SPOOL SPOOL NO. /

No. SUPPORT TYPE PAINT CODE RESULT REMARKS
DRAWING SUPPORT QTY
1

10

11

12

13

14

15

16

17
NOTE: 1) All relevant in-process inspection and NDE requirements shall be completed before releasing to the following:
Surface Preparation/ Painting
Cement Lining
Galvanizing
Epoxy Coating
Others

Sub Contractor QC
Acceptance Contractor QC Inspector Company QC Inspector
Inspector
Name

Signature

Date

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VS3160-003-A-2013 REV .F1

Kuwait National Petroleum Company (K.S.C.)

Clean Fuels Project - Project Coordination Group- EPC PKG-1

System No: Tag ID: ITR No.:

Leak Test Report for Reinforcing Pad

NFI NO.: PCWBS NO.: DATE:
TAG/ID DESCRIPTION: DWG. NO. & REV. NO.:
REFERENCE STD.:

Accept /
S.N. Spool Dwg. No. Line Class Joint No. Remarks
Reject

NOTES:
1) Air test with test pressure =
2) Holding time =
3) Pressure Gauge Serial No.: _____________________ Pressure Gauge Range: ____________________________

Sub Contractor
Acceptance Contractor QC Inspector Company QC Inspector
QC Inspector
Name

Signature

Date

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